Liquid-impermeable mattress cover

ABSTRACT

A mattress cover  1  comprising an upper layer  2   a  having a hem  5,  a padding  3  provided under the upper layer  2   a,  and a liquid-impermeable backing layer  4,  wherein the liquid-impermeable layer  4  is fastened to the upper layer  2   a,  at the hem  5  of the upper layer  2   a  and at least at two or more additional points  10.

The present invention relates to mattress covers, also known as mattress protectors or pads, and in particular to mattress covers that are impermeable to liquid such as water, sweat, urine etc.

BACKGROUND OF THE INVENTION

Different types of protection are used to protect bed mattresses against e.g. urine. It is particularly relevant at hospitals and nursery homes, but it may also be desired at e.g. hotels or in private homes. A simple solution is to place a plastic film under the sheet, but that is uncomfortable to lie on due to the accumulated heat, the noise, and the relatively low friction and thereby sliding of the sheet on the plastic film. Furthermore, these products are often disposable or non-washable. The mattress protection item is often desired to provide a certain comfort as well as protecting the mattress from liquids such as urine and sweat. Mattress covers are known in the art, having a quilted padded bolster, and a liquid-impermeable layer fastened to the bolster along the edges thereof. Such mattress covers are very difficult to handle in a washing and drying process and in the succeeding making of the beds. The reason is that the impermeable layer and the rest of the mattress cover are movable relative to each other and therefore easily form folds in the impermeable layer and/or causes seam slippage. In order to provide a sufficiently impermeable membrane, the impermeable backing layer of these known mattress covers are formed by a laminated liquid-impermeable membrane. A further disadvantage of the known mattress cover is that the laminated impermeable layer makes a noise when the person lying in the bed moves around.

OBJECT OF THE INVENTION

It is an object of the present invention to provide a mattress cover which is impermeable to liquid, such as water, sweat, urine etc. even after a large number of washes.

It is a further object of the present invention to provide a mattress cover that is comfortable to lie on.

It is a further object of the present invention to provide a mattress cover that is easy to handle in an industrial laundry.

It is a further object of the present innovation to provide a mattress cover that can withstand washing and cleaning at temperatures high enough to remove all unwanted kinds of bacteria, without the cover loosing any of its properties necessary to fulfill its purpose.

SUMMARY OF THE INVENTION

The object of the invention may be obtained by a mattress cover comprising an upper layer having a hem, a padding provided under the upper layer, and a liquid-impermeable backing layer, wherein the liquid-impermeable layer is fastened to the upper layer at the hem of the upper layer and at least at two or more additional points. The mattress cover may further comprise a lower layer between the padding and the liquid-impermeable layer.

In one embodiment the upper layer and the padding are joined by quilting.

In a preferred embodiment the liquid-impermeable layer is fastened to the upper layer and the padding by inverted stitching so that the liquid-impermeable layer is not penetrated by the stitching. Hereby it is obtained that the liquid-impermeability of the mattress cover is maintained and the layer is fixed.

The liquid-impermeable layer may be fastened to the upper layer and the padding by quilting. Alternatively, the liquid-impermeable layer may be fastened to the upper layer and the padding by pin-sonic or other heat setting processes.

Alternatively or additionally, in an embodiment the padding is made from polyester hollow fibres or other synthetic fibres.

Alternatively or additionally, in an embodiment the fabric of the liquid-impermeable layer is made from polyester, polyurethane or other synthetic composition.

In the choice of material for the mattress cover, it must be ensured that it can be completely disinfected from unwanted bacteria through an industrial washing process, and that the fibres maintain their other properties (e.g. liquid-impermeability, colour, softness, strength etc) when submitted to such washing processes. By forming the various parts of the mattress cover in synthetic fibres this can be obtained at lower washing temperatures than what is necessary for natural fibres such as cotton or other celluloid fibres.

In an embodiment, the liquid-impermeable layer comprises a laminated fabric.

In another embodiment, the liquid-impermeable layer of the mattress cover comprises a fabric having a liquid impermeable coating. The coating of the liquid-impermeable layer may preferably be made from polyurethane, acrylic or the like. Alternatively, the liquid-impermeable layer may be formed by a laminated fabric.

In any of the above mentioned embodiments, the mattress cover may further comprise a peripheral skirt, adjustable straps, anchor style elastic bands in combination or as individual methods for fixation of the mattress cover on a mattress.

The object of the invention may also be obtained by a method of manufacturing a mattress cover comprising an upper layer having a hem, a padding provided under the upper layer, and a liquid-impermeable backing layer, said method comprising the steps of: joining the upper layer and the padding; fastening a liquid-impermeable layer to the upper layer at the hem of the upper layer and at least at two or more additional points.

In one embodiment of the method of manufacturing a mattress cover the liquid-impermeable layer is fastened to the upper layer and the padding by inverted stitching so that the liquid-impermeable layer is not penetrated by the stitching.

In an embodiment the liquid-impermeable layer is fastened to the upper layer and the padding by quilting. Alternatively, the liquid-impermeable layer is fastened to the upper layer and the padding by pin-sonic or other heat setting processes.

In an embodiment the liquid impermeable layer is provided by coating a sheet of synthetic fibres.

The invention is particularly useful in hospitals, nursery homes and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following the invention and in particular preferred embodiments thereof will be described in detail with reference to the drawings in which:

FIG. 1, schematically and in a sectional view shows a prior art mattress cover formed by a tick having a padding, and a liquid-impermeable layer fastened thereto;

FIG. 2 shows schematically and in a sectional view a mattress cover according to an aspect of the invention;

FIG. 3, in a perspective view, shows an embodiment of the mattress cover shown in FIG. 2 before the liquid-impermeable layer 4 is fastened thereto;

FIG. 4, schematically and in a sectional view shows a mattress cover according to another aspect of the invention;

FIG. 5, in a perspective view, shows an embodiment of the mattress cover shown in FIG. 4; and

FIG. 6, in a sectional view shows the mattress cover shown in FIG. 3, further comprising a peripheral skirt for fixation of the mattress cover on a mattress;

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 shows, schematically, a prior art mattress cover 1 comprising a tick 2 formed by an upper layer 2 a and a lower layer 2 b, a padding 3, and a liquid-impermeable layer 4. The liquid-impermeable layer 4 is only fastened to the tick 2 at the hem 5 thereof.

FIGS. 2 and 4 show a mattress cover 1 according to two aspects of the invention. According to the first aspect of the invention shown in FIG. 2, the tick of the mattress cover 1 comprises an upper layer 2 a and a lower layer 2 b, a padding 3 there between and a liquid permeable layer 4, forming a backing of the mattress cover 1.

FIG. 3 shows schematically that the tick 2 and the padding 3 are joined e.g. by quilting before the liquid-impermeable layer 4 is fastened thereto. The actual pattern of the quilting may differ from the one illustrated in FIG. 3. The liquid-impermeable layer 4 is fastened to the tick 2 at the hems 5 and a number of positions (10, see FIG. 6) across the surface, where the fastening positions may follow the quilting pattern . The fastening should be carried out by a method that does not destroy the liquid-impermeable coating such as inverted quilting/stitching which does not penetrate the liquid-impermeable layer 4. The quilting/stitching must penetrate the padding 3 and the upper layer 2 a for proper fixation of these layers, or it may only involve the liquid-impermeable layer 4 and the lower layer 2 b adjacent thereto (if layer 2 b is used). The quilting/stitching may be made in any desired pattern. An alternative method for fixation may be pin-sonic or other known heat setting processes.

According to the second aspect of the invention shown in FIG. 4, the mattress cover 1 comprises an upper layer 2 a, a padding provided under the upper layer 2 a and a liquid permeable membrane or layer 4 forming a backing for the mattress cover and substituting the lower layer 2 b in the first aspect of the invention.

In both aspects, the liquid-impermeable layer 4 comprises a fabric and a coating (not shown) or a laminated fabric. When a coating is used, the coating is preferably added to the fabric before the joining of the mattress cover 1 to ensure an even and liquid-impermeable surface. The coating may typically be polyurethane, but other materials, such as PTFE, that ensure the liquid impermeability of the layer may also be used.

For all embodiments, the properties of the materials must not be significantly influenced by a large number of washes at temperatures high enough to ensure the necessary cleaning of the actual material used for the mattress cover 1. As an example, the mattress cover 1 may be made from polyester fabric for the tick 2 and hollow polyester fibres for the padding 3. The fabric of the liquid-impermeable layer 4 may also be polyester which may have a looser texture than the tick 2.

Fastening of the liquid-impermeable layer 4 to the rest of the mattress cover 1 ensures that they do not move relative to each other. Thereby both the handling of a mattress cover 1, such as during washing and making of the bed is improved compared to a mattress cover 1 where the layers are only joined at the hem 5.

The impermeability of the mattress cover 1 may be tested e.g. by simply pouring a glass of water on the upper fabric 2 a of the mattress cover 1 and checking that is it does not penetrate the liquid-impermeable layer 4. Since the product is expected to have to be washed a large number of times, it must also be ensured that it is still liquid-impermeable after a significant number of washes at the necessary temperatures.

The impermeability of the mattress cover has been tested in accordance with DS/EN 20811:1993 by accredited laboratory. Furthermore the mattress cover has been tested in accordance with and complies with DS/EN 1276 and DS/EN 1040. These tests performed on mattress covers having tick made from synthetic fibres at both 60° and 95° wash.

FIG. 6 shows schematically a sectional view of a mattress cover 1 having a peripheral skirt 6 to cover, wholly or partly, the sides of a mattress (not shown) on which the mattress cover 1 is placed. A purpose of such a skirt 6 is to keep the mattress cover 1 in place both when making the bed and when the bed is in use. Another purpose may be to protect the sides of the mattress, and still another purpose may be for aesthetic reason. The skirt 6 may have an elastic band 7 at the hem 5 to ease the placing of the mattress cover 1. It may also comprise other means for placing and keeping the mattress cover in position, such as adjustable straps or anchor style elastic bands (not shown). Such straps or elastic bands may also be used for fastening a mattress cover not comprising skirts.

The above describes a mattress cover but it is also within the scope of the invention to concept for making other products such as pillow covers/protectors/pads, seat covers for cars, blankets etc. 

1. A mattress cover comprising an upper layer having a hem, a padding provided under the upper layer, and a liquid-impermeable backing layer, wherein the liquid-impermeable layer is fastened to the upper layer at the hem of the upper layer and at least at two or more additional points.
 2. A mattress cover according to claim 1, wherein the upper layer and the padding are joined by quilting.
 3. A mattress cover according to claim 1, wherein the liquid-impermeable layer is fastened to the upper layer and the padding by inverted stitching so that the liquid-impermeable layer is not penetrated by the stitching.
 4. A mattress cover according to claim 3, wherein the liquid-impermeable layer is fastened to the upper layer and the padding by quilting.
 5. A mattress cover according to claim 1, wherein the liquid-impermeable layer is fastened to the upper layer and the padding by pin-sonic or other heat setting processes.
 6. A mattress cover according to claim 1, wherein the padding is made from polyester hollow fibres or other synthetic fibres.
 7. A mattress cover according to claim 1, wherein the fabric of the liquid-impermeable layer is made from polyester or other synthetic composition.
 8. A mattress cover according to claim 1, wherein the liquid-impermeable layer comprises a laminated fabric.
 9. A mattress cover according to claim 1, wherein the liquid-impermeable layer comprises a fabric having a liquid-impermeable coating.
 10. A mattress cover according to claim 9, wherein the coating of the liquid-impermeable layer is made from polyurethane, acrylic or the like.
 11. A mattress cover according to claim 1, further comprising a peripheral skirt, adjustable straps, anchor style elastic bands in combination or as individual methods for fixation of the mattress cover on a mattress.
 12. A method of manufacturing a mattress cover comprising an upper layer having a hem, padding provided under the upper layer, and a liquid-impermeable backing layer, said method comprising the steps of: joining the upper layer and the padding; fastening a liquid-impermeable layer to the upper layer at the hem of the upper layer and at least at two or more additional points.
 13. A method of manufacturing a mattress cover according to claim 12, wherein said liquid-impermeable layer is fastened to the upper layer and the padding by inverted stitching so that the liquid-impermeable layer is not penetrated by the stitching.
 14. A method of manufacturing a mattress cover according to claim 13, wherein the liquid-impermeable layer is fastened to the upper layer and the padding by quilting.
 15. A method of manufacturing a mattress cover according to claim 13, wherein the liquid-impermeable layer is fastened to the upper layer and the padding by pin-sonic or other heat setting processes.
 16. A method of manufacturing a mattress cover according to any of claim 12 wherein the liquid impermeable layer is provided by coating a sheet of synthetic fibres. 